Vermiculite Alternative For Packaging Material

ABSTRACT

An apparatus and a method are provided for a latex-based packaging material configured to provide a dust-free alternative to vermiculite packaging materials. The latex-based packaging material comprises a portion of a latex-based waste formulated into a recycled latex emulsion, and a portion of particulate material into which the recycled latex emulsion is mixed so as to form a latex-based pulp. In some embodiments, additional components, such as any of various plasticizers, coloring agents, or hardeners, may be included in the latex-base pulp. The latex-based pulp is dispensed and dried so as to form the latex-based packaging material in a variety of desired shapes. Drying may be accomplished by way of unaided atmospheric evaporation, or by way of various conventional drying methods. In some embodiments, the desired shape of the packaging material comprises latex-based packaging peanuts suitable for separating and cushioning forces between containers during transportation in a larger container.

PRIORITY

This application is a continuation application and claims the benefit ofU.S. patent application Ser. No. 15/857,444, filed Dec. 28, 2017, nowU.S. Pat. No. 10,093,791, which is a divisional and claims the benefitof U.S. patent application Ser. No. 14/668,594, filed Mar. 25, 2015, nowU.S. Pat. No. 9,856,367, the entirety of said applications areincorporated herein by reference.

FIELD

The field of the present disclosure generally relates to recycling ofcertain waste. More particularly, the field of the present disclosurerelates to recycling of latex paints and other similar materials to beutilized as an ingredient in a packaging material which may be used asan alternative to vermiculite-based packaging materials.

BACKGROUND

Latex paint is in exceedingly common usage not only by the generalpublic but also by businesses. In recent years there has been adirection of movement from solvent-based paint to the latex type ofpaint. The main objection to a solvent-based paint is to its emissionwithin the air of a petroleum based substance which when breathed isbelieved to be damaging to humans and is also potentially explosive. Theresult has been a substantial increase in the volume of usage of latexpaints which similarly increased the waste of latex paint.

Whenever a decision is made to paint a given structure, invariably therewill be provided an amount in excess of that which is actually needed.This excess becomes waste which usually is discarded. Disposal of latexpaint within landfills has been increasingly objected to, which hasresulted in increasingly restrictive state, local, and federalregulations, requiring that latex paint waste is to be handled ashazardous waste. As will be appreciated, since disposing of hazardouswaste is extremely expensive, it is desirable and advantageous toinstead use the hazardous waste in a process which produces other usefulmaterials, thereby eliminating a need for disposing of the hazardouswaste.

Packaging materials are widely used industrially and domestically tocushion products ranging from delicate equipment to office supplies soas to prevent damage to the products during shipment and handling.Suitable packaging materials often are composed of an expanded foamproviding a low density, flexible packaging that protects a product fromdamage without adding significantly to the weight of the product whenshipped. Although conventional expanded foam materials adequatelycushion a product, disposal of the materials is difficult because theymay not be biodegradable or recyclable.

Several problems are associated with conventional packaging materials,such as expanded polystyrene peanuts. Safety problems arise duringmanufacture because the peanuts are formed from styrene monomer which ishazardous to workers if inhaled or ingested. The packaging peanuts alsoaccumulate static charges that cause them to stick to a product when thepeanuts are closely packed around the product within a shipping carton.Another disadvantage associated with the polystyrene peanuts arises whenthe packaged product is a breakable container filled with a solvent,solution, or other liquid. If the container breaks during shipment, oris not sealed properly, the liquid will leak throughout the shippingcarton. Polystyrene peanuts do not absorb the liquid to minimize suchleakage, and often shrink considerably when exposed to liquid, losingtheir cushioning effect. Furthermore, the nonbiodegradable peanuts areoften discarded after use, adding to existing landfill waste disposalproblems.

Expanded vermiculite is a moisture absorbent packaging material which issuitable for packaging glass containers filled with liquid. Vermiculite,however, exhibits fine dust which adheres to glass and plastic. The finedust can contaminate solvents and damage electronic equipment when thedust remains on the products after being unpackaged. Although a productmay be sealed with a packaging film, the fine dust often sticks to theproduct as it is being removed from the film. Vermiculite is alsoenvironmentally harmful because it is not biodegradable and cannot berecycled.

Starch based formulations have also been used to prepare biodegradablepackaging materials. Starch based peanuts, however, may also beunsuitable for packaging breakable containers because they may dissolvein the presence of liquid which may leak from the containers. Starchbased products also tend to become tacky when exposed to conditions ofhigh humidity which may exist upon shipping and handling of a product.

Recycled newspaper has been used to form a biodegradable, recyclablepackaging material. These materials, formed from aqueous slurries ofchopped newspapers, are molded into thin hollow walled shells or areextruded as pellets. Although these materials employ waste papermaterials, they have several drawbacks. Such packaging materials do nothave the cushioning properties and low density provided by expanded foammaterials. The materials also require a significant amount of storagespace before they are reused or transported for recycling.

What is needed, therefore, is a packaging material which overcomes thedisadvantages associated with conventional packaging materials whilealso reducing the need for disposing of latex-based hazardous waste. Thepresent disclosure provides such an improved packaging material.

SUMMARY

An apparatus and a method are provided for a latex-based packagingmaterial configured to provide a dust-free alternative to vermiculitepackaging materials. The latex-based packaging material comprises aportion of a latex-based waste formulated into a recycled latexemulsion, and a portion of particulate material into which the recycledlatex emulsion is mixed so as to form a latex-based pulp. In someembodiments, additional components, such as any of various plasticizers,coloring agents, or hardeners, may be included in the latex-base pulp.The latex-based pulp is dispensed and dried so as to form thelatex-based packaging material in a variety of desired shapes. Dryingmay be accomplished by way of unaided atmospheric evaporation, or by wayof various conventional drying methods. In some embodiments, the desiredshape of the packaging material comprises latex-based packaging peanutssuitable for separating and cushioning forces between containers duringtransportation in a larger container.

In an exemplary embodiment, an apparatus for a latex-based packagingmaterial comprises a portion of a latex-based waste formulated into arecycled latex emulsion; and a portion of particulate material intowhich the recycled latex emulsion is mixed, thereby forming a pulp whichmay be dispensed and dried so as to form the latex-based packagingmaterial in a desired shape.

In another exemplary embodiment, the pulp further comprises portions ofadditional components, such as any of various plasticizers, coloringagents, or hardeners. In another exemplary embodiment, the desired shapecomprises latex-based packaging peanuts suitable for separating andcushioning forces between containers during transportation in a largercontainer.

In another exemplary embodiment, the latex-based waste is recycledliquid latex paint. In another exemplary embodiment, the latex-basedwaste comprises recycled semi-liquid latex paint and coatings. Inanother exemplary embodiment, the particulate material comprises amixture of cellulose and lignin. In another exemplary embodiment, theparticulate material comprises sawdust.

In an exemplary embodiment, a method for preparing a packaging materialcomprises receiving a portion of latex-based waste; formulating thelatex-based waste into a recycled latex emulsion; acquiring a portion ofsuitable particulate material; mixing and blending the latex-basedemulsion with the particulate material so as to form a latex-based pulp;dispensing the latex-based pulp so as to form a desired shape; drying tocure the latex-based pulp into the desired shape; and treating thelatex-based shape to limit moisture absorption.

In another exemplary embodiment, the latex-based waste is recycledliquid latex paint. In another exemplary embodiment, the latex-basedwaste comprises recycled semi-liquid latex paint and coatings. Inanother exemplary embodiment, the particulate material comprisescellulose and lignin. In another exemplary embodiment, the particulatematerial comprises sawdust.

In another exemplary embodiment, mixing further comprises includingportions of additional components, such as any of various plasticizers,coloring agents, or hardeners. In another exemplary embodiment, thedesired shape of the packaging material comprises latex-based packagingpeanuts configured to provide a substantially dust-free alternative tovermiculite packaging peanuts.

In another exemplary embodiment, drying comprises allowing thelatex-based pulp to dry naturally by way of unaided atmosphericevaporation. In another exemplary embodiment, mixing further comprisesincorporating a drying agent or a solidifier so as to reduce the timerequired to complete drying of the latex-based pulp. In anotherexemplary embodiment, the latex-based pulp is dried by way ofconventional drying methods, such as hot air, microwave heating, orradiant infrared heating.

In another exemplary embodiment, regulating a moisture level within thedesired shape. In another exemplary embodiment, regulating comprisesmeasuring a moisture level within the desired shape. In anotherexemplary embodiment, regulating comprises applying additional drying tothe desired shape when too much moisture is measured.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present disclosure in which:

FIG. 1 illustrates an exemplary embodiment of a preparation process fora vermiculite alternative suitable for use as a packaging material.

While the present disclosure is subject to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and will herein be described in detail. Theinvention should be understood to not be limited to the particular formsdisclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth inorder to provide a thorough understanding of the present disclosure. Itwill be apparent, however, to one of ordinary skill in the art that theinvention disclosed herein may be practiced without these specificdetails. In other instances, specific numeric references such as “firstmaterial,” may be made. However, the specific numeric reference shouldnot be interpreted as a literal sequential order but rather interpretedthat the “first material” is different than a “second material.” Thus,the specific details set forth are merely exemplary. The specificdetails may be varied from and still be contemplated to be within thespirit and scope of the present disclosure. The term “coupled” isdefined as meaning connected either directly to the component orindirectly to the component through another component. Further, as usedherein, the terms “about,” “approximately,” or “substantially” for anynumerical values or ranges indicate a suitable dimensional tolerancethat allows the part or collection of components to function for itsintended purpose as described herein.

In general, the present disclosure describes an apparatus and a methodfor a latex-based packaging material configured to provide a dust-freealternative to vermiculite packaging materials. The latex-basedpackaging material comprises a portion of a latex-based waste formulatedinto a recycled latex emulsion, and a portion of particulate materialinto which the recycled latex emulsion is mixed so as to form alatex-based pulp. The latex-based waste is recycled liquid latex paint,or recycled semi-liquid latex paint and coatings. The particulatematerial generally comprises a source of cellulose and lignin, such assawdust. In some embodiments, additional components, such as any ofvarious plasticizers, coloring agents, or hardeners, may be included inthe latex-base pulp. The latex-based pulp is dispensed and dried so asto form the latex-based packaging material in a variety of desiredshapes. Drying may be accomplished by way of unaided atmosphericevaporation, or by way of various conventional drying methods. Further,a drying agent or a solidifier may be included so as to reduce the timerequired to complete drying of the latex-based pulp. In someembodiments, the desired shape of the packaging material compriseslatex-based packaging peanuts suitable for separating and cushioningforces between containers during transportation in a larger container.

FIG. 1 illustrates an exemplary embodiment of a preparation process 100for a vermiculite alternative suitable for use as a packaging material.The preparation process 100 begins at a latex acquisition step 104 and aparticulate material acquisition step 108. In the latex acquisition step104, a suitable portion of latex-based waste is acquired for use in thepreparation process 100. In some embodiments, the latex-based waste isrecycled liquid latex paint. In some embodiments, the latex-based wastecomprises recycled semi-liquid latex paint and coatings. It will beappreciated that the latex-based waste may be acquired by way of variouswaste recycling programs. In some embodiments, the latex-based waste maybe received from any of a variety of institutions, companies,corporations, or other such entities, that perform waste recyclingoperations. Any of various procedures may be used to formulate thelatex-based waste into a recycled latex emulsion suitable for use in theprocess 100.

In the particulate material acquisition step 108, a suitable particulatematerial is acquired for use in the preparation process 100. Preferably,the particulate material is of a variety suitable for forming apackaging material useable as an alternative to vermiculite. In someembodiments, the particulate material comprises cellulose and lignin,such as is found in sawdust. It has been observed that using sawdust inthe preparation process 100 produces a packaging material which exhibitsa substantial reduction of fine dust often encountered withvermiculite-based packaging materials, as described herein.

At a mixing step 112, a suitable portion of the recycled latex emulsionis mixed with a suitable portion of the particulate material. In someembodiments, the mixing step 112 may further comprise including with therecycled latex emulsion and particulate material suitable portions ofadditional desired components, such as by way of non-limiting example,various plasticizers, coloring agents, or hardeners. As will beappreciated, the types and quantities of additional components willdepend upon desired properties of the end-product of the preparationprocess 100. In some embodiments, the mixing may be accomplished by wayof a typical mixing apparatus, such as a pug mill, or other similartank-like container within which an auger is mounted. In someembodiments, the auger is rotated so as to achieve a desired blending ofthe particulate material and the recycled latex emulsion within thetank. It will be appreciated that the recycled latex emulsion operatesas an agglomeration agent to bind the particulate material and theadditional components, thereby forming a latex-based pulp.

Once the mixing step 112 is complete, the preparation process 100advances to a dispensing step 116, wherein the latex-based pulp may bedispensed so as to form a desired shape. It should be understood thatthe latex-based pulp can be formed into any desired shape, such as byway of non-limiting example, latex-based packaging peanuts which providean advantageously dust-free alternative to vermiculite packagingpeanuts. In some embodiments, the latex-based pulp is dispensed by wayof industrial extruders. As will be appreciated, the particulardispensing or extruding machinery will depend upon the desired shape ofthe end-product of the preparation process 100. In some embodiments, thelatex-based pulp may be dispensed by way of food processing extruderswhich are well known in the art and are commercially available from awide variety of manufacturers for the production of cheese puff snackfoods.

After having been dispensed and formed into desired latex-based shapes,the preparation process 100 advances to a drying step 120 wherein thelatex-based pulp is dried and cured in the desired shape. It will beappreciated that a specific method for drying the latex-based pulp, aswell as the amount of time required for drying, will depend upon theparticular shape of the end-product of the process 100. In someembodiments, the latex-based shape is dried naturally by way of unaidedatmospheric evaporation. In some embodiments, a drying agent or asolidifier 124 may be incorporated into the mixing step 112 so as toreduce the time required to complete the drying step 120. Further, insome embodiments the latex-based shape may be dried by usingconventional drying methods, such as by way of non-limiting example, hotair, microwave heating, or radiant infrared heating. For instance, insome embodiments the latex-based shaped may be preliminarily dried byway of microwave heating and then finally dried by way of a hot airfurnace. In some embodiments, cooling methods may be coupled with theheating methods so as to achieve a desired level of moisture within eachcured latex-based shape. Various other methods for drying and curing thelatex-based shapes will be apparent to those skilled in the art withoutdetracting from the spirit and scope of the present disclosure.

Once the drying of the latex-based shape is complete, the preparationprocess 100 advances to a moisture regulation step 128, wherein amoisture level of the latex-based shape is measured. As will beappreciated, the desired level of moisture within the latex-based shapewill depend upon the particular end-product of the preparation process100. When the latex-based shape is found to contain too much moisture,an additional drying step 132 is applied to the latex-based shape.Similar to the drying step 120, in the additional drying step 132 thelatex-based shape may be dried naturally by way of unaided atmosphericevaporation. In some embodiments, the additional drying step 132 maycomprise using conventional drying methods, such as hot air, microwaveheating, or radiant infrared heating to regulate the moisture within thelatex-based shape. Further, a cooling process may be incorporated intothe conventional drying methods so as to achieve a desired level ofmoisture content within the latex-based shape.

Once the desired level of moisture content has been achieved, thepreparation process 100 proceeds to an absorption treatment step 136. Aswill be appreciated, once finished, the latex-based shape may be exposedto moisture from a variety of sources, such as atmospheric moisture ordirect contact with various liquids. An absorption of moisture may havea detrimental effect on the structural integrity of the latex-basedshape. For this reason, protecting the finished latex-based shape fromfuture liquid exposure, due either to atmospheric moisture or directliquid contact, operates advantageously to preserve the structuralintegrity and longevity of the latex-based shape. In the absorptiontreatment step 136, the latex-based shape is surface treated so as tolimit absorption of moisture. In some embodiments, the surface treatmentmay comprise applying a chemical coating to the latex-based shapewherein the chemical coating limits moisture absorption by thelatex-based shape. In some embodiments, the surface treatment maycomprise any of various well known mechanical surface treatments tolimit moisture absorption by the latex-based shape. As will beappreciated by those skilled in the art, a wide variety of surfacetreatments and methods for limiting moisture absorption by thelatex-based may be practiced, without limitation, and within the spiritand the scope of the present disclosure.

Once the desired level of moisture content has been achieved, and thelatex-based shape has been treated to limit future moisture absorption,the preparation process 100 finishes at a step 140 wherein thelatex-based shape is yielded as an end-product, having the desired shapeand properties. Preferably, the end-product is a resilient and absorbentpackaging material. In a preferred embodiment, wherein the end-productcomprises latex-based packaging peanuts, the end-product comprises aresilient, absorbent, and loose packaging material advantageously suitedto be used so as to separate and cushion forces between containersduring transportation in a larger container. As will be appreciated,latex-based packaging peanuts are very well suited for filling voidsdisposed between containers, as well as various other objects, andprovide an advantageously dust-free alternative to vermiculite-basedpackaging peanuts, as mentioned herein. Furthermore, once thelatex-based end-product of the present disclosure reaches an end of itsuseful life, due to physical degradation, the latex-based end-productmay be used as a feedstock for any of various well known waste to energyprocesses, thereby substantially eliminating an environmental impactassociated with conventional packaging materials.

While the invention has been described in terms of particular variationsand illustrative figures, those of ordinary skill in the art willrecognize that the invention is not limited to the variations or figuresdescribed. In addition, where methods and steps described above indicatecertain events occurring in certain order, those of ordinary skill inthe art will recognize that the ordering of certain steps may bemodified and that such modifications are in accordance with thevariations of the invention. Additionally, certain of the steps may beperformed concurrently in a parallel process when possible, as well asperformed sequentially as described above. To the extent there arevariations of the invention, which are within the spirit of thedisclosure or equivalent to the inventions found in the claims, it isthe intent that this patent will cover those variations as well.Therefore, the present disclosure is to be understood as not limited bythe specific embodiments described herein, but only by scope of theappended claims.

What is claimed is:
 1. A latex-based packaging material, comprising: aportion of a latex-based waste formulated into a recycled latexemulsion; and a portion of particulate material into which the recycledlatex emulsion is mixed, thereby forming a pulp which may be dispensedand dried so as to form the latex-based packaging material in a desiredshape.
 2. The packaging material of claim 1, wherein the pulp furthercomprises portions of additional components, such as any of variousplasticizers, coloring agents, or hardeners.
 3. The packaging materialof claim 1, wherein the desired shape comprises latex-based packagingpeanuts suitable for separating and cushioning forces between containersduring transportation in a larger container.
 4. The packaging materialof claim 1, wherein the latex-based waste is recycled liquid latexpaint.
 5. The packaging material of claim 4, wherein the latex-basedwaste comprises recycled semi-liquid latex paint and coatings.
 6. Thepackaging material of claim 1, wherein the particulate materialcomprises a mixture of cellulose and lignin.
 7. The packaging materialof claim 6, wherein the particulate material comprises sawdust.
 8. Amethod for preparing a packaging material, comprising: receiving aportion of latex-based waste; formulating the latex-based waste into arecycled latex emulsion; acquiring a portion of suitable particulatematerial; mixing and blending the latex-based emulsion with theparticulate material so as to form a latex-based pulp; dispensing thelatex-based pulp so as to form a desired shape; drying to cure thelatex-based pulp into the desired shape; regulating a moisture levelwithin the desired shape; and treating the latex-based shape to limitfuture moisture absorption.
 9. The method of claim 8, wherein thelatex-based waste is recycled liquid latex paint.
 10. The method ofclaim 8, wherein the latex-based waste comprises recycled semi-liquidlatex paint and coatings.
 11. The method of claim 8, wherein theparticulate material comprises cellulose and lignin.
 12. The method ofclaim 11, wherein the particulate material comprises sawdust.
 13. Themethod of claim 8, wherein mixing further comprises including portionsof additional components, such as any of various plasticizers, coloringagents, or hardeners.
 14. The method of claim 8, wherein the desiredshape of the packaging material comprises latex-based packaging peanutsconfigured to provide a substantially dust-free alternative tovermiculite packaging peanuts.
 15. The method of claim 8, wherein dryingcomprises allowing the latex-based pulp to dry naturally by way ofunaided atmospheric evaporation.
 16. The method of claim 8, whereinmixing further comprises incorporating a drying agent or a solidifier soas to reduce the time required to complete drying of the latex-basedpulp.
 17. The method of claim 8, wherein the latex-based pulp is driedby way of conventional drying methods, such as hot air, microwaveheating, or radiant infrared heating.
 18. The method of claim 8, whereinregulating comprises measuring a moisture level within the desiredshape.
 19. The method of claim 18, wherein regulating comprises applyingadditional drying to the desired shape when too much moisture ismeasured.